Automotive Batteries

Automotive Batteries
WHAT AND AUTOMTIVE BATTERY DOES A battery supplies power to the starter and

ignition system to start the engine. A battery also supplies the extra power necessary when the vehicle's electrical load exceeds the supply from the charging system.

Automotive Batteries
Automotive batteries acts as a voltage

stabilizer in the electrical system. An automotive battery converts chemical energy into electrical energy An automotive battery evens out voltage spikes and prevents them from damaging other components in the electrical system

Automotive Batteries
What the standby battery does: Supplies electrical power to critical systems in

the event of a power outage. Acts as a voltage stabilizer, to smooth out fluctuations in the electrical generation systems. Temporarily holds large electrical loads as electric utilities switch from one generation system to another.

How a Battery is Made

How a Battery is Made

Batteries are made of

five basic components: 1. A resilient Plastic container. 2. Positive and negative internal plates made of lead.

How a Battery is Made

3. Plate separators

made of porous synthetic material. 4. Electrolyte, a dilute solution of sulfuric acid and water better known as battery acid. 5. Lead terminals, the connection point between the battery and whatever it powers.

How a Battery is Made

Most automotive battery

containers and their covers are made of polypropylene. A typical 12-volt car battery, case is divided into six sections, or cells

Maintenance-Free vs Standard Battery

Normal battery uses up to 50% antimony in

construction of plate grids Greater amount of antimony, greater amount of gassing MF batteries uses calcium, 0.2% calcium equal to 6% antimony. Typical lead-calcium grid uses only 0.090.12% calcium

How a Battery is Made

A battery must have

positive and negative plates to conduct a charge. Grids or plates are made from lead or an alloy of lead and other metals.

How a Battery is Made

A mixture of lead oxide -- which is powdered

lead, sulfuric acid and water is applied to the grids Expander material made of powdered sulfates is added to the paste to produce negative plates The expander material is not added to the positive plates.

How a Battery is Made

Pasted positive and

negative plates must be separated to prevent short circuits. Separators are thin sheets of porous, insulating material used as spacers between the positive and negative plates.

How a Battery is Made

Fine pores in the

separators allow electrical current to flow between the plates while preventing short circuits.

How a Battery is Made

A positive plate is paired

with a negative plate and a separator to make an element There is one element per battery cell Elements are dropped into the cells in the battery case The cells are connected with a metal that conducts electricity.

How a Battery is Made

The lead terminals, or

posts, are welded on. The battery is then filled with electrolyte - or battery acid -- a mixture of sulfuric acid and water, and the cover is attached.

How a Battery is Made

After a battery is made its is

Checked for leaks. Charged for several hours. Labels added

Battery Operation
A battery convert chemical energy into

electrical energy When an atom loses and electron it become a positively charge Ion When an atom gains an electron it become a negatively charge ion. Battery produce Voltage and Amperage.

Voltage is defined and electrical pressure Amperage is defined as electron flow from one atom to another.

Battery Operation
Electrolyte in automotive batteries is a

solution of 36% sulfuric acid and 64% water. Electrolyte is used for both lead-antimony and lead-calcium batteries. Additional electrolyte is must never be added to any battery after the original electrolyte fill Added only pure distilled water if level of electrolyte reduced, because of gassing

Battery Operation
When you have and abundance of negatively

charge ions and a abundance of positively charged ions connected together in an electrical circuit current will begin to flow. The larger the difference between the positive ions and the negative ions the greater the voltage or electrical pressure difference. The greater the flow electrons from one atom to another the greater the current flow

Battery Operation
Battery have two different ratings. 1. Cold cranking amperage (CCA): Is the

ability of a battery to maintain 7.2 volts for 30 seconds at 0 degrees F. (1.2 volts/cell) 2. Reserve Capacity (RC): Is the ability of a battery to supply 10.5 volts at 25 amps at 80 degrees F. (no. of minutes the battery can produce 25amps and still have 1.75 volts/cell)

Battery Operation
A battery stores electricity for future use. A battery develops voltage from the chemical

reaction produced when two unlike materials, such as the positive and negative plates, are immersed in electrolyte, a solution of sulfuric acid and water. In a typical lead-acid battery, the voltage is approximately 2 volts per cell, for a total of 12 volts.

Battery Operation
Electricity flows from the battery as soon as

there is a circuit between the positive and negative terminals. This happens when any load that needs electricity, such as the radio, is connected to the battery.

Battery Operation

Battery Operation
When a battery is discharge the plates have

the same amount of electrical charge. As a battery discharges, the lead plates become more chemically alike, the acid becomes weaker and less voltage is produced.

Battery Operation
You can recharge a discharged battery by

feeding electrical current back into the battery. A full charge restores the chemical difference between the plates and leaves the battery ready to deliver its full power.

Battery Operation

Batteries
SPECIFIC GRAVITY

Specific gravity means exact weight. A "Hydrometer" or a "Refractometer" compares the exact weight of electrolyte with that of water. Strong electrolyte in a charged battery is heavier than weak electrolyte in a discharged battery. By weight, the electrolyte in a fully charged battery is about 36% acid and 64% water.

Batteries
The specific gravity of water is 1.000. Acid is 1.835 times heavier than water, so its

specific gravity is 1.835. The electrolyte mixture of water and acid has a specific gravity of 1.270, usually stated as "twelve and seventy."

Battery Operation
This unique process of discharging and

charging in the lead-acid battery means that energy can be discharged and restored over and over again. This is what's known as the cycling ability in a battery.

Specific Gravity vs State of Charge and Battery Voltage

Specific gravity 1.265 1.225 State of charge Fully charged 75% Battery voltage 12.6 or higher 12.4

1.190
1.155 Lower than 1.120

50%
25% Discharged

12.2
12.0 11.9 or lower

Battery Quiz
1. What supplies power to the ignition and the starting system

A. Starter motor B. Battery C. Alternator D. None of the above

Battery Quiz
2. What component acts as a voltage stabilizer in the electrical system?

1. Voltage regulator 2. Current regulator 3. Battery 4. Alternator

Battery Quiz
3. How many cell is in an automotive battery

A. 12 B. 6. C. 4 D. 2

Battery Quiz
4. Each cell of an automotive battery will supply how many volts?

A. 2 B. 4 C. 10 D. 12

Battery Quiz
5. A mixture of sulfuric acid and water is called:

A. Battery liquid B. Battery activator C. Electrical charge D. Electrolyte

Battery Quiz
6. A battery must have ______________ to conduct electricity.

A. Negative plates only B. Positive plates only C. Positive and Neutral plates D. Positive and Negative plates

Battery Quiz
7. Most automotive battery containers and their covers are made of:

A. Steel B. Wood C. Soft plastic D. polypropylene

Battery Quiz
8. After a battery is made its is:

A. Charged for several hours B. Check for leaks C. Has labels added D. All the above

Battery Quiz
9. A _________ supplies the extra power necessary when the vehicle's electrical load exceeds the supply from the charging system. A. Alternator B. Starter C. Fuel cell D. Battery

Battery Quiz
10. You can recharge a discharged battery by:

A. Turning the headlights on B. Replacing the electricity that has been removed C. Removing the positive battery cable D. Replacing the Negative battery cable

Battery Quiz
11. Technician A says a fully charge battery should have a specific gravity of:

A. 1.130 B. 1.220 C. 1.260 D. 1.270

Battery Quiz
12. What tool is used to measure battery specific gravity?

A. Milometer B. Micrometer C. Kilometer D. Hydrometer

Battery Quiz
13. Electrolyte is a mixture of sulfuric acid and _____________ :

A. Hydrogen B. Carbon C. Sulfuric carbon D. Water

Battery Quiz
14. This unique process of discharging and charging a lead-acid battery is called:

A. Discharging B. Cycling C. Overcharging D. None of the above

Batteries
Battery are rated in both cold cranking amps and reserve capacity. Cold Cranking Amps is the amount of amperage a battery can supply at 0 Degrees while maintaining 9.6 volts for 30 seconds Reserve capacity: The amount of time a battery can supply 10 volts at 25 amps when not being charged

Charging Batteries
When a battery becomes discharged it must

be recharged. A battery can be charged by the vehicle alternators or by an external battery charger When connecting or disconnecting a battery charger care should be taken not to create a spark.

Charging Batteries
When connecting or disconnecting a battery

charger care should be taken not to create a spark.

Hydrogen and oxygen can explode Spark will cause a battery to explode The gasses created during charging are explosive

Charging Batteries
When charging a battery always connect the

positive cable first and the negative cable last When removing battery cables disconnect the Negative cable first and the Positive cable last. Most automotive manufactures recommend disconnecting a battery before its recharged.

Charging Batteries
Warning: hydrogen gases produced by a

charging battery are very explosive. Keep sparks, flames and lighted cigarettes away from battery Always wear eye protection and proper clothing Avoid wearing any jewellery when performing work near battery.

Charging Batteries
To charge the battery means to pass and

electric currrent through the battery in an opposite direction than during discharge. When connecting the charger to battery, make sure the charger is turned off. Connect the cables leads to battery terminal, observing polarity. Attempting to charge battery while cables is reversed will result in battery damage.

Charging Batteries
Slow Charging

The charge rate is between 3 to 15 amperes for a long period of time. Advantages: It is the only way to restore the battery to a fully charged state and to minimizes the chances of overcharging Slow Charging causes the lead sulfate on the plates to convert to lead peroxide and sponge lead throughout the thickness of the plate.

Charging Batteries
Fast Charging

Uses a high current for a short period of time to boost the battery Will bring the state of charge up high enough to crank the engine.However it is unable to recharge the battery as effectively as slow charging. Only converts the lead sulfate on the outside of plates Do not fast charging more than 2 hours, excessive fast charging can damage the battery

Charging Batteries
Charge rate

is the speed at which the battery can safely be recharged at a set amperage. Charge rate required to recharge battery depends on:
1. 2. 3. 4.

Battery capacity (high capacity, longer time) State of charge Battery temperature Battery condition

Battery Test
Battery Terminal Test To check for poor electrical connections between the battery cables and terminals Use a voltmeter to measure voltage drop across the cables and terminals. Connect the negative voltmeter test lead to the cable clamp and connect the positive meter lead to battery terminal Crank the engine and observe the voltmeter reading If voltmeter shows over 0.3V, there is high resistance at cable connection.

Battery Test
Leakage Test

Battery drain can be caused by a dirty battery The dirt can allow current flow over the battery case. This current flow is like leaving a light on Set voltmeter to a low DC volt scale. Connect the negative lead to negative terminal Move the red test lead to across top and sides of battery case. If the meter reads voltage, there is a complete path through the dirt

Other Battery Test

Hydrometer Optical Refractometer Open circuit voltage test Capacity test

MINI PROJECTS

ELE 665 AUTOMOTIVE ELECTRONICS

Basic Rules
Team Members 4 to 5 members/team Stricly adhere to dateline No Plagiarisme Budget limitation less than RM300.

Mini Projects
12V Batteries Indicator 12V Lead Acid Battery Charger Adaptive Windscreen Wiper Control Passive Keyless Door Lock Using RFID CAN Based Vehicle Security System LIN Based Anti Pinch Window

Proposal
Front Page Teams name & members name & position Abstract Introduction Problem Statement Project Goals and Objective Background of Study Methodology Design Budget Gantt Chart Team Member Responsibilities Project Deliverables Summary References Presentation on 17/10 & 24/10 Presentation on 10/10

Important Dates
Progress Report 1 Presentation - 2 Nov

TEST 1 16 Nov
Progress Report 2 Presentation 23 Nov
Progress Report 3 Presentation 5 Dec

TEST 2 14 Dec Final Report & Presentation 19 & 21 Dec